Formula Student Germany

Workshop 2009 in Abstatt

Preparation for dynamics

Creating a Future for Engineers

Preparation for dynamics

1. Testing
2. Coordination
3. Driver

Thomas Hennings
Sebastian Seewaldt
Michael Kissling

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Testing
Why testing?
Test ground
Test schedule
Test crew
Drivers
Preparation for testing
Documentation
Safety

Creating a Future for Engineers

Why testing?
The first thing the car should
do is to run reliable.
Sounds easier as it is!

Creating a Future for Engineers

Why testing?
The first thing the car should
do is to run reliable.
Sounds easier as it is!
Second: get a fast car and a
fast driver.

Creating a Future for Engineers

Why testing?
Finally you need to learn to
understand and trust your
car.
Understanding is important
for:

?
?

Vehicel dynamics
Failures
Statics!!!

Drivers have to trust the car,

than they can go fast!
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Test ground
Its not always easy to find a
adequate test ground.
Important factors are safety,
noise and space.
No curbs, trees, etc.
Possible:
Parking lots
Air fields
Test facilities from companies
Creating a Future for Engineers

Test ground
Its not always easy to find a
adequate test ground.
Important factors are safety,
noise and space.
No curbs, trees, etc.
Possible:
Parking lots
Air fields
Test facilities from companies

X
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Test ground
Its not always easy to find a
adequate test ground.
Important factors are safety,
noise and space.
No curbs, trees, etc.
Get a insurance for your
team. It is worth the money!

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Test schedule
1. Let the car roll

Comp simul.
Performanc
e

2. Fix the broken parts

3. Setup for essential
components e.g.

Shifting system

Engine

4. Suspension setup
5. Simulation of the whole
competition
6. While all steps driver training!

10

[weeks]
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12

Test schedule
What happens if you have
less time for testing?
Same amount of problems.

Comp simul.
Performanc
e

Less time for performance

testing and driver training!

10

[weeks]
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12

Test schedule
What happens if you have
less time for testing?
Same amount of problems.

Comp simul.
Performanc
e

Less time for performance

testing and driver training!

With just a few tesing days

90% DNF chance
0

10

[weeks]
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12

Test crew
For high efficiency and
safety small group of
people. E.g. 6-8 people.
Should contain a member of
every department.
At the end of test phase
suspension guys are more
important.

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Drivers
Test driver = competition driver
Every driver gets faster with more
training.
The driver has to do what the chief
tells him (tiny little brains). Otherwise
he/she should not drive.
They have to be there at every test
day!
They need a good physical fitness.
At the end the driver has to
implement the work of the whole
team!
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Test preparation
Car must be ready to run the
day before testing.
The evening before testing
short test run.
Check list for packing!
Todo list for testing.

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Check list for packing

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Test equipment must have

Basic engine sensors
Oil/water temp.
Oil pressure

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Test equipment must have

Basic engine sensors
Oil/water temp.
Oil pressure

IR-gun with thermo couple

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Test equipment must have

Basic engine sensors
Oil/water temp.
Oil pressure

IR-gun with thermo couple

Manometer e.g. 0-2 bar

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Test equipment must have

Basic engine sensors
Oil/water temp.
Oil pressure

IR-gun with thermo couple

Manometer e.g. 0-2 bar
Stopwatch

Creating a Future for Engineers

Test equipment must have

Basic engine sensors
Oil/water temp.
Oil pressure

IR-gun with thermo couple

Manometer e.g. 0-2 bar
Stopwatch
Make sure drinks and food
are available.
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Money for testing?

Tires are the expensive part.
Ca. 600 per set
You should get min. 1 set of
NEW tires. 2 are better.
Try to get used tires. For the
first part of testing you could
use any tire.

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Documentation
Write the minutes!
So other team members can
be up to date.
You directly have a todo list
for the workshop.
If similar problems recur,
you can check the
cirumstances.

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Documentation
While performance testing
especially suspension
parameters are important.
Write them down!
Comment them in your test
log!

Than you have different

setups for competition.

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Documentation
Write a tire book.
Every tire should be marked.
Best would be to write down
every heat cycle.
Watch the tire! You can learn
a lot from the thread wear!

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Safety
Especially with student built
prototype cars very
important!
Almost everything can
happen.
Even at competition you can
see flying wheels or burning
cars.

Creating a Future for Engineers

Safety
Especially with student built
prototype cars very
important!
Almost everything can
happen.
Even at competition you can
see flying wheels or burning
cars.

Creating a Future for Engineers

Safety
Especially with student built
prototype cars very
important!
Almost everything can
happen.
Even at competition you can
see flying wheels or burning
cars.

Creating a Future for Engineers

Safety
...
What can you do?
Always drive with full driver
protection.
Always leave a lot space
between your track and
obstacles.
Always have your fire
extinguisher with you.
Dedicate one person as fire man.
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Coordination
Setting off to the competition
Scrutineering
Tilt, Noise and Brake
Dynamics
Endurance

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Setting off to the competition

Use testing checklist as
guide
Bring all other spare parts
too (sheet metal, screws,)
Think of different szenarios
Think of how to carry all
your stuff at the eventsite

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Setting off to the competition

Bring tested tyre protection
Mount the correct tyres at
home
Bring enough rims
Maybe scrub the tyres at
home

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Scrutineering
Follow the inspection sheet,
test scrutineering with
alumnis
Get the car scrutineering
proof as soon as possible
after the rollout
In doubt: Ask, change or
backup

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Tilt, Noise and Brake

Test it at home!
Bring a backup muffler

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Dynamics
Define the 4 Dynamic Area guys for the whole event
Define the belt-on-guy for the endurance
Define the drivers in the early testing phase latest
Check, but dont over check the car in the evening

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Dynamics
Warm up the engine early enough
Fuel up enough
dont wait too long
Dont do panic setup changes
Ride height changes can lead to bad
wheel load distribution

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Endurance
Check damper setting and
tyre pressure
Warm up the engine early
enough
Fuel up early enough
Dont knock cones

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Dynamics : The driver

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How to form your own famous driver

Driver casting :

Find your driver raw material

Driver training :

Give him a shape

Testing :

Effective use of your driver

Competition :

Your driver needs perfect conditions to perform well

to become YOUR famous driver

Ergonomics :

The drivers workplace

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Driver casting
Driver raw material should have the following qualities:
Talent
Reliability
Willing to spend extra time (weekends!)
Be part of the team
Character: calm, sensible, no prima donna behaviour

How to cast?
Karting, testing with old cars
Important: Driver decision as early as possible 6 drivers

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Driver training Shaping your driver

Testing time is valuable Only drivers are allowed to drive
First decision: Who drives which dynamic event
Get to know the car drive, drive, drive. Dont hassle with performance setup!
Build tracks similar to Formula Student tracks
Use cones, mark and count them, try to avoid Off Courses
Practice dynamic events under competition conditions
Practice difficult situations confidence for your driver
Physical fitness is important and gives you mental fitness

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Testing Effective use of your driver

Drivers have tiny little brains at least as soon as they sit in the car
One dedicated person that communicates with the driver
This person and only THIS person, tells the driver what to do
The driver cant see whats going on behind the main hoop DANGER!

Important for performance setup testing: constant laptimes

Listen to your driver talk to your driver
Drivers should write feedback sheets

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Competition dynamics The driver is your front man

The drivers only task is to drive as fast as possible and make no mistakes
Keep stress away from him on dynamic days his focus is driving
In queue: one team member with eye contact
Driver has to trust the team team has to trust the driver
Drivers are nervous and need to be looked after
Eat in time and drink enough
Stay calm, watch other cars, take a nap
Dont sit in the car for hours (in the sun)

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Ergonomics The drivers workplace

My car is my castle feeling comfortable helps a driver go fast
Build the car around the driver
Think about different drivers

Seat : should give precise feedback what the car is doing

Steering forces : dont underestimate them
Driver should not look like this

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See you at Hockenheim

August 2010

Creating a Future for Engineers